Apparatus for forming a polymeric web

ABSTRACT

The present invention is directed to an apparatus for forming a multi-layer web formed from at least two polymeric film tubes in intimate contact with each other but not bonded to each other. The apparatus includes the use of a blown film extrusion die that extrudes two separate blown film polymeric tubes via two separate annular die lips. A fluid cooling system applies cooling fluid across a plurality of surfaces of the two blown film tubes. One of the die lips may be at a different height from the other die lip. The frost line of one blown film tube may be at a different height from the other blown film tube.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 15/075,689,filed on Mar. 21, 2016, and is hereby incorporated by reference intothis disclosure.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates generally to an apparatus and method for forminga multilayer polymeric web from two or more polymeric film tubes formedfrom a single blown film extrusion die. More particularly, thisinvention relates to an apparatus and method for forming and cooling atleast pair of molten plastic film tubes exiting a pair of outlet lips ofan extrusion die in a blown film process to form a continuous webcomprising multiple layers of film.

2. Description of the Related Art

Thin plastic film may be produced, in addition to other manufacturingmethods, by extruding plastic material, such as polyethylene resin orother similar polymeric resins, in a process known as blown filmextrusion. In a typical blown film extrusion process, resin is fed intoa single extruder where an extrusion screw pushes the resin through theextruder. The extrusion screw compresses the resin, heating the resininto a molten state under high pressure. The molten, pressurized resinis fed through a blown film extrusion die typically having a singleannular opening or die lip. As the molten material is pushed into andthrough the extrusion die, a molten plastic film tube emerges from theoutlet of the extrusion die. The film tube is fed into a set of niprollers above the die which pull the tube upwards and collapses tube.

The plastic film tube is blown or expanded to a larger diameter byproviding a volume of air within the interior of the tube. Thecombination of the volume of air and the plastic film tube is commonlyreferred to as a bubble between the extrusion die and a set of niprollers. The plastic film tube is commonly cooled by one or moreexternal air rings applying a constant flow of air upward along theoutside of the plastic film tube. The ratio between the initial diameterof the tube as it exits the die and its final diameter after it expandsis commonly referred to as the blow up ratio (BUR). A number of factorsincluding, but not limited to, the air pressure within the bubble of theplastic film tube, the cooling rate provided by the air ring, thetemperature and flow of material out of the extrusion die, and the rateat which the plastic film tube is pulled by the nip rollers impact theblow-up ratio, the ultimate diameter of the plastic film tube, and theultimate thickness or gauge of the plastic film tube.

As the plastic film tube cools travelling upward toward the nip rollers,the plastic film tube solidifies from a molten state to a solid stateafter it expands to its final diameter and thickness. The point alongthe bubble where the plastic film solidifies is known as the frost line.Consequently, the portion of the bubble below the frost line is moltenallowing for expansion and thinning of the plastic film tube.Conversely, the portion of the bubble above the frost line hassolidified and the diameter and thickness of the plastic film tube isgenerally fixed at that point. Furthermore, since the film above thefrost line has solidified, it tends not to adhere to itself or otherfilms that it may come into contact with.

Improved cooling of the plastic film increases the stability of thebubble, thereby allowing for more accurate control of the physicalproperties of the plastic film tube, for a broader range of plastic filmtube diameters and thicknesses, and improved throughput rates. Tofacilitate better cooling, it is known in the art to use an internalbubble cooling, or IBC, assembly to dissipate heat from within theinterior of the bubble. Without an IBC assembly, the bubble contains astatic volume of air applying outward pressure on the plastic film tubebut there is no avenue to dissipate the heat absorbed by the staticvolume of air from the plastic film tube. Consequently, the interior airvolume quickly settles at approximately the same temperature as theplastic film tube, providing no cooling benefit. Internal bubble coolingassemblies exchange the warm air within the bubble with cooler air whilemaintaining a constant pressure. The cooled air within the bubbleabsorbs heat from the interior surface of the bubble, cooling theplastic film tube more quickly and lowering the frost line for increasedbubble stability.

U.S. Pat. No. 7,753,666 issued to Greg Wood on Jul. 13, 2010, andentitled Apparatus and Method for Cooling Plastic Film Tube in BlownFilm Process (hereafter, “the Wood Patent”) describes an improvedinternal bubble cooling assembly using particular air ring assemblies.The internal air ring assemblies improve the flow of the cooled airwithin the bubble to provide improved bubble stability and allow forimproved properties of the plastic film tube. The teachings andspecification of the Wood Patent are incorporated herein by reference.

A bubble comprising more than one layer may be formed via blown filmextrusion, which is commonly referred to as coextrusion. In coextrusion,more than one discrete annular layer of film is formed within theextrusion die. Typically, each layer is provided to the die from aseparate extruder. This enables different polymeric resins withdifferent physical properties to be combined into a single bubble. Intypical coextrusion, each layer is combined and placed into intimatecontact with each other within the interior of the die and prior toexiting a single annular die lip. Since each layer is in a molten statewhen combined, the films laminate together, if the resins are compatiblewith each other.

Coextruded films allow for forming a singular film with multiplelaminated layers with the layers bonded to each other on a molecularlevel. However, it is known that certain material properties of thelaminate negatively influence the material properties of the laminate.For instance, the laminate typically inherits the tear strength of thelayer with the weakest tear strength. Hence, when tear strength is acritical property for a web, it is undesirable to form a coextruded filmwith a resin having a low tear strength with another resin having arelatively strong tear strength, even though such a combination mayprovide other desirable properties. Thus, it would be advantageous for ablown film extrusion process that forms multiple layers of film withdistinct properties with adjacent layers in contact with each other, butwhere the layers are not bonded to each other. With such a process, thelayers of the web would maintain their own properties, such as tearstrength, and the web could have multiple layers without a layer with alower tear strength decreasing the tear strength of an adjacent layer.

U.S. Publication No. 2014/0334749 by Michael G. Borchardt “the BorchardtApplication”), et. al, entitled Melt-Bonded Thermoplastic Bags withTailored Bond Strength and Methods of Making the Same, describes forminga bubble with multiple layers with a separate die exit for each layer.The Borchardt Application describes bringing together the molten filmfrom the two layers below at least the frost line of one of the layerssuch that the inner and outer layers are bonded together. However, TheBorchardt Application fails to disclose allowing both bubbles to fullycool below the molten state before coming into contact with each other.Hence, the Borchardt Application requires the utilization of othermeasures to prevent the physical properties of one layer from degradingthe physical properties of the other layer. The Borchardt Applicationalso fails to address the decrease in throughput typical of extrudingmultiple layers due to the difficulties presented in adequately coolingthe multiple tube of polymeric film to maintain an acceptable frost lineelevation.

In view of the foregoing, it would be desirable to provide a method offorming a multilayer web from a bubble in bubble process that maintainsa throughput rate more typical of high speed commercial operations. Itwould also be desirable for the method to provide for a multi-layer webwhere the layers are un-bonded to each other so that each layermaintains its own physical properties, such as tear and dart impact. Thepresent invention addresses these needs.

SUMMARY OF THE INVENTION

The present invention is directed to an apparatus and method for forminga multi-layered polymeric web from multiple collapsed tubes of polymericfilm. In one embodiment of the present invention, the apparatus includesa first source of a first molten polymer and a second source of a secondmolten polymer. The embodiment further includes a blown film extrusiondie comprising an annular outer die lip and an annular inner die lip.The inner die lip is surrounded by the outer die lip. The first moltenpolymer is extruded upwardly out of the outer die lip to form an outerpolymeric film tube having an outer frost line. The second moltenpolymer is extruded upwardly out of the inner die lip to form an innerpolymeric film tube surrounded by the outer polymeric film tube. Theinner polymeric film tube has an inner frost line. A height of the innerfrost line is different from a height of the outer frost line. An outerbubble external cooling source directs fluid onto an exterior of theouter polymeric film tube. Furthermore, an inner bubble interior coolingsource directs cooling fluid onto an interior of the inner polymericfilm tube.

In some embodiments of the present invention, an elevation of the outerdie lip may be different from an elevation of the inner die lip. Theouter die lip may be at a lower elevation than the inner die lip. Theheight of the outer frost line may be lower than the height of the innerfrost line. An intermediate cooling source may direct cooling fluid ontoan interior of the outer polymeric film tube and an exterior of theinner polymeric film tube. An intermediate exhaust may exhaust coolingfluid from an interior of the outer polymeric film tube and an exteriorof the inner polymeric film tube. An interior inner bubble exhaust mayexhaust cooling fluid from the interior of the inner polymeric tube.

In further embodiments of the present invention, a set of nip rollersmay be located above the inner and outer frost lines. The set of niprollers can simultaneously collapse the inner and outer polymeric filmtubes. Furthermore, a characteristic of the first molten polymer may bedifferent from a characteristic of the second molten polymer. Thecharacteristic of the first molten polymer differing from thecharacteristic of the second molten polymer may be due to a coloringagent added to one of the first and second molten polymers.

In a further embodiment of the present invention, a multi-layeredpolymeric film tube is formed by a process. In the process a firstsource of a first molten polymer and a second source of a second moltenpolymer are provided. A characteristic of the first molten polymer maydiffer from a characteristic of the second molten polymer. The firstmolten polymer is extruded from an outer die lip of an extrusion diesuch that an outer polymeric film tube is formed with an outer frostline. The second molten polymer is extruded from an inner die lip of theextrusion die such that an inner polymeric film tube is formed with aninner frost line. The inner die lip is surrounded by the outer die lipand the inner frost line is at a different height than the outer frostline. Cooling fluid is directed onto an exterior of the outer polymericfilm tube by an outer bubble external cooling source. Cooling fluid isalso directed onto an interior of the inner polymeric film tube by aninner bubble interior cooling source. The outer and inner polymerictubes are collapsed so that the tubes are placed into intimate contactwith each other without bonding to each other.

In certain embodiments of the present invention, cooling fluid from asingle cooling fluid supply may be directed onto an interior of theouter polymeric film tube and an exterior of the inner polymeric filmtube. Additionally, the first molten polymer may comprise a differentcolor than the second molten polymer.

In a further embodiment of the present invention, an apparatus forms amulti-layered web from multiple tubes of polymeric film. The apparatusincludes a first extruder that extrudes a first molten polymeric stream.The apparatus further includes a flow splitter that splits the firstmolten polymeric stream into a second polymeric stream and a thirdpolymeric stream. Additionally, a static mixer mixes at least oneadditive to the second polymeric stream. A first die path supplies thesecond polymeric stream to a first die lip and a second die pathsupplies the third polymeric stream to a second die lip. The first dielip extrudes a first polymeric tube from the second polymeric stream andthe second die lip extrudes a second polymeric tube from the thirdpolymeric stream. The second die lip is located within the first dielip. A set of nip rollers collapses the first and second polymeric tubesand places the tubes in intimate contact with each other without the twotubes being bonded together.

In particular embodiments of the present invention, the first die lipmay be at a lower height than the second die lip. Furthermore, the firstpolymeric tube may have a first frost line and the second polymeric tubemay have a second frost line. Additionally, the first frost line may belower than the second frost line. An interior of the first polymerictube and an exterior of the second polymeric tube may be both cooled bya cooling fluid supplied by a single cooling source. The secondpolymeric tube may further comprise a high stalk.

BRIEF DESCRIPTION OF THE RELATED DRAWINGS

A full and complete understanding of the present invention may beobtained by reference to the detailed description of the presentinvention and described embodiments when viewed with reference to theaccompanying drawings. The drawings can be briefly described as follows.

FIG. 1 provides a schematic elevation view of a bubble-in-a-bubble blownfilm extrusion process according to one embodiment of the presentinvention.

FIG. 2 provides a cross-sectional perspective view of an embodiment ofthe invention shown schematically in FIG. 1.

FIG. 3a provides a simplified cross-section, for the sake of clarity, ofthe embodiment of the invention shown in FIG. 2.

FIG. 3b provides a detailed cross-sectional perspective view of a lowerportion of the embodiment shown in FIG. 2 with directional arrowsshowing various flow directions of cooling fluid. The directional arrowsform no part of the invention and are shown for reference only.

FIG. 4 provides a cross-sectional elevation view of an intermediatecooling source of the embodiment shown in FIGS. 2 and 3.

FIG. 5 provides a schematic elevation view of single extruder processaccording to an embodiment of the present invention.

FIG. 6 provides a schematic elevation view of a dual extruder processaccording to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure illustrates one or more embodiments of thepresent invention. It is not intended to provide an illustration orencompass all embodiments contemplated by the present invention. In viewof the disclosure of the present invention contained herein, a personhaving ordinary skill in the art will recognize that innumerablemodifications and insubstantial changes may be incorporated or otherwiseincluded within the present invention without diverging from the spiritof the invention. Therefore, it is understood that the present inventionis not limited to those embodiments disclosed herein. The appendedclaims are intended to more fully and accurately encompass the inventionto the fullest extent possible, but it is fully appreciated that certainlimitations on the use of particular terms is not intended toconclusively limit the scope of protection.

FIG. 1 illustrates a schematic overview of a blown film extrusion system100, according to one embodiment of the present invention, for producingplastic film utilizing a blown film extrusion process. Polyethyleneresin, in the form of pellets, is fed into one or more extruders (notshown). The pellets are heated in the one or more extruders until thepolyethylene resin is molten. The one or more extruders supply twoindependent sources of molten polymer, a first polymer source 101 o, anda second polymer source 101 i. The molten material is fed under pressurethrough an extrusion die 102 having two independent annular openings.Each annular opening of the die may be referred to as a die lip.

As further shown in FIG. 1, extrusion die 102 can then extrude twomolten plastic film tubes, outer tube 106 o, and inner tube 106 i formedby the two annular die lips. The two tubes then form two blown filmpolymeric bubbles, outer bubble 110 o, and inner bubble 110 i. Alsoshown in FIG. 1 are two frost line regions, outer frost line region 112o, and inner frost line region 112 i, where the two correspondingbubbles transition from a molten polymeric film to a solid material. Thelocation at which the outer and inner tubes 106 o and 106 i expand tocome into contact with each other is shown as the bubble-to-bubblecontact point 140 in FIG. 1. For ease of reference throughout thisdisclosure the character “o” is used in reference to the outer bubbleand related features while the character “i” is used in reference to theinner bubble and related features within the accompanied drawings.

Nip rollers 108 are also shown in FIG. 1 at the top of bubbles 110 o and110 i. Nip rollers 108 pull tubes 106 o and 106 i up and away from die102. Tubes 106 o and 106 i are also simultaneously collapsed by niprollers 108 as each tubes passes through nip rollers 108. Since niprollers 108 flatten both tubes 106 o and 106 i, the nip rollers 108 forman enclosed volume for each tube, the outer bubble 110 o and innerbubble 110 i, which correspond to the outer and inner tubes 106 o and106 i.

Internal fluid pressure within each bubble 110 o and 110 i appliesoutward pressure on each plastic film tube 106 o and 106 i, leading tothe diameter of each bubble 110 o and 110 i expanding. As each plasticfilm tube 106 o and 106 i rises, it cools, solidifying from a moltenstate to a solid state as it expands to its final diameter andthickness. As used throughout this disclosure, the term tube typicallyrefers to the tubular shaped film extruded from each die lip and theterm bubble typically refers to the tubular structure of film and thevolume encased by the tubular structure between the corresponding dielip and nip rollers. However, the terms tube and bubble may be usedinterchangeably throughout the disclosure due to the closeinter-relationship between the two terms in the blown film extrusionprocess.

As further shown in FIG. 1, a cooling system 114 can be provided to coolthe two bubbles as they form to maintain a commercially reasonablethroughput rate. The cooling system 114 decreases the time required forthe molten polymer to cool to a solid film. As shown in FIG. 1, an outerbubble external cooling source 116, an intermediate cooling source 118,and an inner bubble interior cooling source 120 can be included withcooling system 114. Outer cooling fluid source 117 can supply coolingfluid to the outer bubble external cooling source 116 while innercooling fluid supply 123 can supply cooling fluid to intermediatecooling source 118 and inner bubble interior cooling source 120. In analternative embodiment, each cooling source can have separate coolingsupplies or a single cooling supply may supply each cooling source.

Shown in FIG. 2 is a detailed cross-sectional view of an embodiment ofthe blown film extrusion system shown schematically in FIG. 1. Ingeneral, the majority of features of blown film extrusion system 100 aresymmetric about common axis A as shown in FIGS. 3a, 3b , and 4, whichextrusion die 102 and cooling system 114 are centered about.

Shown in FIG. 2 is extrusion die 102. Extrusion die 102 has two separateannular die paths 102 o and 102 i. Molten polymeric resin is fed to diepaths 102 o and 102 i. As better shown by FIG. 3a , each die path leadsto a separate annular die lip with die path 102 o delivering moltenpolymer to outer die lip 104 o and die path 102 i delivering moltenpolymer to inner die lip 104 i. From a horizontal perspective, inner dielip 104 i is encircled or encompassed by outer die lip 104 o; and from avertical perspective, inner die lip 104 i is elevated above outer dielip 104 o.

As the molten material is extruded from each die lip 104 o and 104 i,separate molten plastic film tubes 106 o and 106 i emerge. Outer die lip104 o extrudes outer plastic or polymer film tube 106 o and inner dielip 104 i extrudes inner polymeric film tube 106 i. Since inner die lip104 i is within outer die lip 104 o, inner tube 106 i is located withinouter tube 106 o.

In at least one embodiment, one or both of film tubes 106 o and 106 imay comprise multiple discrete layers of polymeric resin formed by acoextrusion process as known in the art where multiple layers arecombined in the die prior to exiting from the die. Since the layers areextruded together in a molten state, the layers are bonded to adjacentlayers, presuming that adjacent layers comprise compatible resins.

The height or location at which each tube transitions from a moltenpolymer to a solid polymer is typically referred to as a frost line.Since the polymer is solidified once above the frost line, the filmtypically fails to expand any further above the frost line. The frostline for a given blown film extrusion process can vary depending uponprocess conditions. Hence, the relative desired range of the frost linecontemplated by the invention is shown by frost line regions 112 o and112 i in FIGS. 1 and 2.

Outer frost line region 112 o corresponds to outer tube 106 o and outerbubble 110 o. Inner frost line region 112 i corresponds to inner tube106 i and inner bubble 110 i. The lower portion of each plastic filmtube below frost line regions 112 o and 112 i is generally molten whilethe upper portion of each plastic film tube above each correspondingfrost line region is generally solid. The inner frost line region 112 iis shown at a relatively lower height in FIG. 1 in comparison to thelocation of inner frost line region shown in FIG. 2.

The invention contemplates that outer tube 106 o transitions from amolten polymer to a solid polymer at a different height than inner tube106 i and prior to coming into contact with inner tube 106 i. Hence, asshown in FIGS. 1 and 2, the outer frost line region 112 o is located ata lower elevation or height than the inner frost line region 112 i. Asfurther shown by FIGS. 1 and 2, outer tube 106 o transitions into asolid polymer prior to coming into contact with inner tube 106 i. Innertube 106 i continues to expand until reaching its frost line withininner frost line region 112 i and coming into contact with outer tube106 o at contact point 140.

The frost line of inner tube 106 i is ideally controlled so that frostline of inner tube 106 i is at or just below the contact point 140 asshown by FIG. 1. Since the frost line of the inner tube may varyslightly, it is contemplated that the inner tube frost line may beslightly above the bubble-to-bubble or tube-to-tube contact point 140 asshown by FIG. 2. However, it is understood in the art that a blown filmpolymeric bubble gradually transitions from a molten state to a solidstate.

As the film of a blown film bubble approaches closer to the frost line,the film gradually transitions from a molten to a solid state. Hence,the invention contemplates that even if the contact point 140 is reachedprior to the inner bubble becoming fully solidified as shown in FIG. 2,the film of the inner tube will not bond with the film of the outer tubesince contact point 140 is substantially adjacent to frost line region112 i and inner tube 106 i has transitioned substantially from a moltento a solid prior to reaching contact point 140.

In at least one embodiment of the invention, inner tube 106 i may notexpand to the same or a substantially similar diameter for the innertube 106 i to come into contact with the outer tube 106 o when expanded.However, the two tubes will still come into contact with each when theypass through nip rollers 108 and are collapsed on to each other. Such anarrangement ensures that inner tube 106 i has fully transitioned tosolid film prior to coming into contact with outer tube 106 o. Oncepassing through the nip rollers 108, the film of the two tubes will beplaced in intimate contact with each other, but the outer edges offlattened inner tube 106 i will be slightly recessed from the outeredges of flattened outer tube 106 o.

Depending upon the resin composition of the inner and outer tubes andprocess conditions, the two films may experience a certain amount ofblocking, but the invention contemplates that the two adjacent films donot bond to each other. Whether the films of the inner and outer tubesbond to each other is partly dependent upon the material of the twofilms and, in particular, each film's crystallinity. Thus, the inventioncontemplates that in one preferred embodiment, use of a linearlow-density polyethylene (LLDPE) or low-density polyethylene (LDPE)polymer for the outer tube 106 o and a high-density polyethylene (HDPE)polymer for the inner tube 106 i may be used to assist in preventing thefilm of the two tubes from bonding to each other.

Other polymers, such as nylon or polypropylene, may be used inconjunction with each other or with polyethylene polymers, which mayalso provide for non-adherence between the individual tubes. Inconjunction with incompatible polymers or standing alone, one or moreadditives may be used to prevent the film of the tubes from adhering toeach other. For instance, calcium carbonate (CaCO₃) may be added to thepolymer of one or both tubes during the extrusion process to assist inpreventing the film of the two tubes from adhering to each other. Use ofCaCO₃ may also be used in one of the tubes or to a greater extent in thepolymer of one of the tubes, such as the outer tube, to lower the frostline of the tube since CaCO₃ increases the cooling rate for a givenmolten polymer.

Rather than varying the composition of individual tubes to preventbonding between adjacent surfaces of the outer and inner tubes 106 o and106 i, materials may be injected between the bubbles of the two tubes toprevent bonding of the adjacent surfaces. For instance, a vaporized oratomized liquid may be injected between the two bubbles 110 o and 110 iof the outer and inner tubes 106 o and 106 i during the blown filmextrusion process. Such a liquid can be utilized to accelerate thecooling of the adjacent surfaces of the outer and inner bubbles 110 oand 110 i by lowering each surface's temperature. Furthermore, theinjected liquid could include a volatile scented compound to add apleasing scent to the final product. Adding a scented compound inbetween the layers may be an alternative to adding a scented compound tothe molten polymers as is commonly known in the art for forming scentpolymeric bags. The liquid could also include anti-blocking agents toprevent the layers from adhering or blocking with each other.

Rather than a liquid, dry materials such as a finely granulated orpowder-like substance may be injected between the two bubbles. Such adry material may be injected between the layers with the use of thecooling fluid of the intermediate cooling source as a carrier of thepowder-like substance. The powder-like substance may have anti-blockingor scented properties as discussed above regarding an injected liquidmaterial.

The rate at which the film of the outer and inner tubes 106 o and 106 icool and hence the height of their frost lines may be controlled byadditional methods. For instance, the film of the outer tube 106 o maybe formed thinner than the film of the inner tube 106 i; and henceencourage cooling of outer tube 106 o at a faster rate since lessmaterial per a given length will require cooling. Furthermore, theamount of cooling fluid delivered to the outer tube 106 o may be greaterthan the amount of cooling fluid delivered to the inner tube 106 i. Agreater amount of cooling fluid delivered to the outer tube 106 o thanto inner tube 106 i will encourage cooling of the outer tube at a fasterrate and hence assist in moving its frost line lower in relation to thefrost line of the inner tube 106 i. The temperature of the cooling fluiddeliverer to the outer tube 106 o can also be lower, or its coolingcapacity increased, to also encourage faster cooling of the outer bubble106 o.

Controlling the final diameter and film thickness of each plastic filmtube 106 o and 106 i are, among other factors, the air pressure withinthe interior of each plastic film tube or bubble, the cooling rateprovided by cooling system 114, the speed of the nip rollers 108, andthe amount of resin pushed through each extrusion die lip 102 o and 102i by the one or more extruders. Most importantly in the presentinvention, embodiments of cooling system 114 are disclosed to facilitatethe forming of outer tube 106 o and inner tube 106 i within desireddimensions, process conditions, and at commercially reasonablethroughput rates.

As shown in FIG. 2 and more clearly in FIGS. 3a and 3b , cooling system114 provides cooling fluid to at least a lower area of an externalsurface of outer tube 106 o and in internal surface of inner tube 106 i.The cooling fluid may comprise ambient air, chilled ambient air, acryogenic fluid mixture such as liquid nitrogen used to cool ambient orchilled air, or air chilled additionally by an evaporative liquidinjected into the cooling fluid. Cooling system 114 may also provide forthe exhausting of the inputted cooling fluid from any enclosed volume ofthe extrusion system, such as the interior of inner bubble 110 i and theenclosed volume between the outer and inner bubbles 110 o and 110 i.

As previously mentioned, FIGS. 3a and 3b illustrate an enlarged partialview of the embodiment of the present invention shown in FIG. 2. Asshown in the depicted embodiment, the cooling system 114 can provideboth external and internal cooling for both the outer and inner tubes106 o and 160 i. Cooling system 114 can include an outer bubble externalcooling source 116, intermediate cooling source 118, and inner bubbleinterior cooling source 120.

Shown furthest from the center of the polymeric tubes in FIGS. 3a and 3bis an outer bubble external fluid source 116 directing cooling fluid onto an external side of the outer tube 106 o. Outer bubble externalcooling source 116 may comprise an air ring with a cooling fluid supply117 and supply outlet 119. Further incorporated into the outer bubbleexternal cooling source 116 may be an air ring lip 121 to assist incontrolling the cooling fluid exiting supply outlet 119 and theexpansion of outer bubble 110 o.

As further shown in FIGS. 3a and 3b , with certain aspects shown moreclearly in FIG. 4, an intermediate bubble cooling source 118 can belocated inside the outer bubble 106 o and outside the inner bubble 106i. Intermediate bubble cooling source 118 may include an outer outlet118 o and inner outlet 118 i. Intermediate cooling source 118 may be inthe general form of an air ring. The cooling source 118 may be centeredabout the vertical axis A, as shown in FIGS. 3a, 3b and 4. The coolingsource 118, in general, may have an annular shape with opposing annularshaped horizontal walls 412 and 420 extending away from the verticalaxis A, as shown in FIG. 4. The cooling source 118 may further haveopposing inner and outer annular shaped vertical walls 440 and 430extending parallel and offset from the vertical axis A and followinginner and an outer circumferences of cooling source 118.

As shown best by FIG. 4, intermediate cooling source 118 may have astaggered, a stair-step, or vertically offset construction toaccommodate the different elevations of outer and inner die lips 104 oand 104 i, as shown in FIGS. 3a and 3b . This vertically offsetconstruction leads to an additional annular shaped upper inner verticalwall 410 with a smaller diameter than a diameter of annular shaped lowerinner vertical wall 440, with upper inner vertical wall 410 above lowerinner vertical wall 440. This vertically offset construction allows forintermediate air supply 118 to supply cooling fluid to the interiorsurface of outer bubble 110 o and the exterior surface of inner bubble110 i of FIGS. 1 and 2, while efficiently utilizing the available spaceprovided by the offset height or elevation difference of outer and innerdie lips 104 o and 104 i as shown by FIGS. 1-3.

Returning to FIGS. 3a and 3b , outer and inner supply outlets 118 o and118 i are shown supplied by separate fluid supplies 130 o and 130 i. Inan alternative embodiment, both outer and inner outlets 118 o and 118 imay be supplied by a common fluid supply. Further shown in FIG. 3b areone or more baffles that can control the amount of cooling fluidsupplied to outer outlet 118 o and inner outlet 118 i.

As also shown in FIGS. 3a and 3b , the outer outlet 118 o may directfluid on to the interior surface of the outer tube 106 o and the inneroutlet 118 i may direct fluid on to the exterior surface of the innertube 106 i. The outer outlet 118 o may direct fluid on to the interiorsurface of the outer tube 106 o due to it being defined along the outercircumference of the cooling source 118 along the outer vertical wall430.

As shown in FIGS. 3a, 3b and 4, the inner outlet 118 i of intermediatecooling source 118 may direct cooling fluid on to the external surfaceof the inner bubble 106 i due to the inner outlet 118 i being definedbelow upper inner vertical wall 410 of cooling source 118. The upperinner vertical wall 410 may have defined in it inner outlet 118 i with agenerally annular opening so that the exit of fluid from the coolingsource 118 through inner outlet 118 i is at least partly controlled by agap between the outer circumference of the stalk of the inner tube 106 iand the inner diameter of the cooling source 118. As shown in FIGS. 3aand 3b , cooling fluid exiting outlet 118 i may impede directly upon alower bottom exterior surface of inner bubble 106 i immediately aboveinner die lip 104 i.

Further shown in FIGS. 3a and 3b , between the outer and inner bubbles106 o and 106 i is a common exhaust 124. Common exhaust 124 exhausts thecooling fluid supplied by the outer and inner outlets 118 o and 118 i ofthe intermediate cooling fluid supply 118. Common exhaust 124 may becomprised of a plurality of vertical tubes dispersed circumferentiallyabout vertical axis A of FIGS. 3a and 3b . Each opening of the pluralityof tubes may be elevated above the outlets of the intermediate coolingfluid supply so that the cooling fluid flows about the surfaces of theinner and outer bubbles prior to returning through common exhaust 124.

Prior to the cooling fluid entering common exhaust 124, the coolingfluid may pass through an exhaust shroud 126 covering the common exhaust124 as shown in FIGS. 3a and 3b . The exhaust shroud 126 may have agenerally annular shape, be placed above common exhaust 124, and have agenerally continuous annular slit 128 on an external wall of the exhaustshroud to evenly distribute the partial vacuum and evacuation of fluidfrom the volume between the outer and inner bubbles 110 o and 110 i.

In an alternative embodiment to the blown film extrusions system shownin FIGS. 1-3, the intermediate cooling source may not be provided inwhat otherwise is a similar blown film extrusion system for forming amulti-layered polymeric web of film. Rather than an intermediate coolingsource that exchanges cooling fluid in the volume defined between theouter and inner bubbles 110 o and 110 i, a static volume of air or othergaseous fluid, such as nitrogen, may be utilized to fill the enclosedvolume between the two bubbles. A static volume of fluid can provide thenecessary pressure to maintain the desired gap between the outer andinner bubbles 110 o and 110 i. However, since the volume of fluid isstatic, the ability for the system to cool the two bubbles decreasesdramatically. Hence, the throughput, or processing speed may increasesignificantly compared to the process disclosed by FIGS. 1-3 utilizingthe above discussed intermediate cooling source 114.

Further shown in FIGS. 3a and 3b is an inner bubble interior coolingsource 120 which provides internal bubble cooling (IBC) to the interiorsurface of the inner bubble 106 i. With the use of a high-stalk innerbubble, the outlet 120 a of the inner bubble interior cooling source 120may be located above the stalk of the inner bubble, as shown in FIGS. 3aand 3b . The outlet may be a simple annular shaped opening at the end ofa riser 120 b of the inner bubble interior cooling source located withinthe stalk of the inner bubble. The riser 120 b may be formed from anouter cylindrical wall and an inner cylindrical wall with cooling fluidsupplied between the two cylinders.

Further shown in FIGS. 3a and 3b may be provided an inner bubble exhaust122. The exhaust 122 may be provided to exhaust the cooling fluidsupplied to the interior of the inner bubble by the inner bubble coolingsource 120. In at least one embodiment, the exhaust 122 may be locatedwithin the inner bubble cooling source 120. An inlet of the exhaust maybe in the shape of an inverted cone located above the cooling source120. The inverted cone directs the cooling fluid supply towards theinterior surface of the inner bubble and helps to accumulate the fluidsupply into exhaust 122.

As further shown in FIG. 2 and in greater detail in FIGS. 3a and 3b ,inner die lip 104 i may be at a higher elevation than outer die lip 104o. In one particular embodiment, inner die lip 104 i may have a diameterof approximately seven inches and outer die lip 104 o may have adiameter of approximately eighteen inches. Furthermore, in the sameembodiment, inner die lip 104 i may have an elevation approximately fourinches higher than outer die lip 104 o. The difference in height orelevation between the two die lips is shown as H in FIG. 3a . Thedifferences in die lip elevations provides additional space betweeninner tube 106 i and outer tube 106 o for locating an intermediatebubble cooling source 118 as shown in FIGS. 2 and 3. In at least onealternative embodiment (not shown), both die lips of the die may be atthe same elevation.

As further illustrated in FIGS. 3a and 3b , additional space may also beprovided for intermediate cooling source 118 by utilizing a high-stalkbubble for inner bubble 110 i. However, a traditional lower stalk bubblemay also be used as contemplated by the invention. A high-stalk bubblerefers to a bubble where the diameter of the extruded plastic film tuberemains relatively constant with the die lip diameter for a considerabledistance after exiting the die lip. In one particular embodiment, asshown in FIGS. 3a and 3b , the inner die lip 104 i diameter may beapproximately seven inches and the stalk height of inner film tube 106 imay be approximately 42-70 inches prior to the inner tube 106 ibeginning to expand into its final diameter after reaching the frostline within frost line region 112 i. The final diameter of inner filmtube 106 i, which in certain embodiments may be shared with outer filmtube 106 o, may be approximately 38 inches.

In at least one embodiment, the formation of inner film tube 106 i witha high-stalk bubble may be aided with the use of a high molecular weight(HMW) polymeric resin. Furthermore, due to the relative small initialdiameter of the inner film tube 106 i, the blow up ratio (BUR) of thetube may be considerably larger, as shown in FIGS. 1-2, than the BUR ofouter film tube 106 o. The BUR defines the ratio between the initialdiameter of a blown film tube after exiting the die to its finaldiameter at its frost line. In the above discussed example, the BUR ofthe inner film tube is approximately 5.4:1 while the BUR of the outerfilm tube is approximately 2:1. A ratio between the BUR of the outer andinner film tubes may also be calculated, with the above discussed ratioof the BUR calculated to be approximately 2.6:1.

Now turning to FIGS. 5 and 6, two alternative embodiments for providingtwo distinct molten polymer sources to die 102 are illustrated. Each ofthe embodiments provides a means for delivering two polymer streams withdistinctive characteristics from the other to each die path 102 o and102 i.

One alternative is illustrated by FIG. 5. FIG. 5 shows blown filmextrusion system 500 with molten polymer extruded by a single extruder502 and exiting the extruder 502 as a single first polymer stream 505.The first polymer stream 505 is shown flowing into a splitter or flowdivider 504 that splits the first polymer stream 505 into two separatestreams: a second polymer stream 505 a and a third stream polymer 505 b.First polymer stream 505 may be divided equally into the second andthird polymer streams 505 a and 505 b or divider 504 may also beconfigured to apportion other various amounts of polymer between the twodownward streams 505 a and 505 b.

Once divided into two separate streams, each polymer stream 505 a and505 b is shown passing through a corresponding gear pump 506 a or 506 b,or similar pump device, to increase each polymer stream's pressure. Onceeach polymer stream exits one of the gear pumps, it is shown passingthrough a corresponding static mixer, a first static mixer 508 a orsecond static mixer 508 b.

Prior to entering each gear pump or static mixer, one or more additivesor resin modifiers may be added to each polymer stream. The one or moreadditives may consist of a colorant, another resin modifier such as aslip agent, or a combination of additives. The addition of the one ormore additives may be used to modify a characteristic of one of thepolymer streams 505 a and 505 b such that one polymer stream has atleast one characteristic different from the other polymer stream. Sincethe disclosure, in at least a preferred embodiment, contemplates the useof a gear pump and static mixer, the one or more additives or resinmodifiers would preferably be in the form of a liquid supplied by aliquid pump. In an alternative embodiment, a dedicated extruder may beused to supply modifiers in solid form to the extruder and then suppliedto the resin stream at the same location in molten form.

When each polymer stream 505 a and 505 b pass through a correspondingstatic mixer, the one or more additives are distributed throughout eachflow of molten polymer. Once the two separate polymer streams 505 a and505 b pass through a corresponding static mixer, the separate polymerstreams are shown in FIG. 5 flowing into a separate die path of die 510.The separate dies paths can be the die paths 102 o and 102 i as shown bypreviously discussed FIGS. 1 and 2. Each polymer stream may then form aseparate polymeric tube, such as outer and inner tubes 106 o and 106 iof FIGS. 1-3 after being extruded out of respective die lips 104 o and104 i.

Rather than the flow being split from a single extruder as discussedabove in regards to FIG. 5, separate extruders may be provided to supplythe molten polymer to each die lip of a multiple lip die, as shown byFIG. 6. Blown film extrusion system 600 comprises two separate extruders602 a and 602 b. In system 600, additives, modifiers, and even theselection of polymeric resins may be varied between first and secondextruders 602 a and 602 b. Each extruder may supply a completelydifferent polymeric resin with distinct additives, or any variationthereof to separate independent die lips.

As shown by FIG. 6, once molten polymer exits extruders 602 a and 602 b,two separate polymer streams are formed, a first polymer stream 605 aand a second polymer stream 605 b. Polymer stream 605 a is shownentering a first die path defined in die 610 and polymer stream 605 b isshown entering a second die path of die 610. Each polymer stream 605 aand 605 b may then form a separate polymeric tube, such as outer andinner tubes 106 o and 106 i of FIGS. 1-3.

Dual extruder blown film extrusion system 600 provides a simpler systemwith greater flexibility in material selection in comparison to singleextruder extrusion system 500. However, single extruder extrusion system500 provides a more efficient system in comparison to system 500 sinceonly one extruder is required. Hence, system 500 allows more efficienttransition from a typical mono-extrusion blown film process to abubble-in-bubble extrusion system as contemplated by the disclosedinvention. System 500 also allows for formation of a multilayer web froma bubble-in-bubble process with each web or flattened tube havingdiffering properties, such as each layer comprising a different colorwhen at least one colorant agent is added to one of the independentpolymer streams 505 a and 505 b.

As previously noted, the specific embodiments depicted herein are notintended to limit the scope of the present invention. Indeed, it iscontemplated that any number of different embodiments may be utilizedwithout diverging from the spirit of the invention. Therefore, theappended claims are intended to more fully encompass the full scope ofthe present invention.

I claim:
 1. An apparatus for forming a multi-layer polymeric web frommultiple collapsed tubes, comprising: a first source of a first moltenpolymer, a second source of a second molten polymer, a blown filmextrusion die comprising: an outer die lip comprising an annularopening, wherein the outer die lip extrudes the first molten polymer toform an outer polymeric film tube having an outer frost line, and aninner die lip comprising an annular opening, the inner die lipsurrounded by the outer die lip, wherein the inner die lip extrudes thesecond molten polymer to form an inner polymeric film tube within theouter polymeric film tube, the inner polymeric film tube having an innerfrost line, and wherein a height of the inner frost line is differentfrom a height of the outer frost line, an outer bubble external coolingsource directing cooling fluid onto an exterior of the outer polymericfilm tube, an inner bubble interior cooling source directing coolingfluid onto an interior of the inner polymeric film tube, and anintermediate cooling source directing cooling fluid onto an interior ofthe outer polymeric film tube and an exterior of the inner polymericfilm tube, wherein the outer and inner polymeric film tubes are placedin intimate contact with each other but not bonded to each other.
 2. Theapparatus of claim 1 further comprising: an elevation of the outer dielip different from an elevation of the inner die lip.
 3. The apparatusof claim 2 further comprising: the outer die lip at a lower elevationthan the inner die lip.
 4. The apparatus of claim 1 further comprising:the height of the outer frost line lower than the height of the innerfrost line.
 5. The apparatus of claim 1 further comprising: anintermediate exhaust that exhausts cooling fluid from an interior of theouter polymeric film tube and an exterior of the inner polymeric filmtube.
 6. The apparatus of claim 1 further comprising: an inner bubbleinterior exhaust that exhausts fluid from the interior of the innerpolymeric tube.
 7. The apparatus of claim 1 further comprising: theheight of the inner frost line and the outer frost line below a locationwhere the inner and outer polymeric film tubes initially come intocontact with each other.
 8. The apparatus of claim 1 further comprising:a characteristic of the first molten polymer different from acharacteristic of the second molten polymer.
 9. The apparatus of claim 8further comprising: the characteristic of the first molten polymerdiffering from the characteristic of the second molten polymer due to acoloring agent added to at least one of the first and second moltenpolymers.
 10. An apparatus for forming a multi-layered tube of polymericfilm, comprising: a first extruder extruding a first molten polymericstream, a flow splitter splitting the first molten polymeric stream intoa second polymeric stream and a third polymeric stream, a static mixermixing at least one additive to the second polymeric stream, a first diepath supplying the second polymeric stream to a first die lip, a seconddie path supplying the third polymeric stream to a second die lip, afirst die lip extruding a first polymeric tube supplied by the first diepath, a second die lip extruding a second polymeric tube supplied by thefirst die path, the second die lip located within the first die lip, anda set of nip rollers collapsing the first and second polymeric tubes andplacing the tubes in intimate contact with each other.
 11. The apparatusof claim 10 further comprising: the first die lip at a lower height thanthe second die lip.
 12. The apparatus of claim 10 further comprising:the first polymeric tube having a first frost line and the secondpolymeric tube having a second frost line, and the first frost linelower than the second frost line.
 13. The apparatus of claim 10 furthercomprising: an interior of the first polymeric tube and an exterior ofthe second polymeric tube both cooled by a cooling fluid supplied by asingle cooling source.
 14. The apparatus of claim 10 further comprising:the second polymeric tube comprising a high stalk.
 15. An apparatus forforming a multi-layer polymeric web from multiple collapsed tubes,comprising: a first source of a first molten polymer, a second source ofa second molten polymer, a blown film extrusion die comprising: an outerdie lip comprising an annular opening, wherein the outer die lipextrudes the first molten polymer to form an outer polymeric film tubehaving an outer frost line, and an inner die lip comprising an annularopening, the inner die lip surrounded by the outer die lip, wherein theinner die lip extrudes the second molten polymer to form an innerpolymeric film tube within the outer polymeric film tube, the innerpolymeric film tube having an inner frost line, and wherein a height ofthe inner frost line is different from a height of the outer frost line,an outer bubble external cooling source directing cooling fluid onto anexterior of the outer polymeric film tube, an inner bubble interiorcooling source directing cooling fluid onto an interior of the innerpolymeric film tube, an inner bubble interior exhaust that exhaustsfluid from the interior of the inner polymeric tube, and the outer andinner polymeric film tubes placed in intimate contact with each otherbut not bonded to each other.
 16. The apparatus of claim 15 furthercomprising: an elevation of the outer die lip different from anelevation of the inner die lip.
 17. The apparatus of claim 16 furthercomprising: the outer die lip at a lower elevation than the inner dielip.
 18. The apparatus of claim 15 further comprising: the height of theouter frost line lower than the height of the inner frost line.
 19. Theapparatus of claim 15 further comprising: an intermediate cooling sourcedirecting cooling fluid onto an interior of the outer polymeric filmtube and an exterior of the inner polymeric film tube.